System and method for flat packed furniture to enable reuse of packaging materials

ABSTRACT

A flat packed furniture system includes a plurality of boxes, each comprising a packaging piece and a set of furniture parts, such that the set of furniture parts is flat packed inside the packaging piece, such that a plurality of parts in the plurality of boxes is configured to be assemblable as a furniture item, which can be a cabinet, such that a plurality of packaging pieces in the plurality of boxes is configured to be reused as packaging for the furniture item. Also disclosed is a method for flat packing furniture, including flat packing, shipping, unpacking, assembling, repacking, and reshipping.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional applicationSer. No. 15/584,924, filed May 2, 2017; which claims the benefit of U.S.Provisional Application No. 62/332,432, filed May 5, 2016; both of whichare incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to the field of flat packedfurniture, and more particularly to methods and systems for flat packingto reduce shipping cost.

BACKGROUND OF THE INVENTION

Flat packing of cabinets and furniture is generally done for the purposeof reducing logistics/transportation costs from themanufacturing/distribution source to the user/consumer.

The packaging design has as a principal purpose of ensuring that theproduct can get to the desired location without damage. The packaging ofmany products is designed with the DIY consumer in mind and does notconsider reuse of any of the packaging materials.

A furniture product that is designed to be initially shipped as a flatpacked product may require multiple flat pack boxes to make a specificassembled stock keeping unit (SKU). Generic sub-assemblies can be usedacross multiple SKUs and may be packed independently of sub-assembliesthat are unique to a specific SKU. These types of products may bereferred to as modular flat packed products.

A growing market is emerging, particularly with more expensivematerials/products, where the flat packed product is shipped to areseller/dealer; the reseller/dealer assembles the product, repackagesthe product as an assembly and delivers it or arranges delivery to theconsumer or the jobsite. The kitchen cabinet industry is an examplewhere this trend is growing.

However, this process entails packaging the product twice, and sincethere is generally no reuse of materials, the manufacturer willconsequently incur significant material and labor costs for repackaging.

As such, considering the foregoing, it may be appreciated that therecontinues to be a need for novel and improved devices and methods forflat packing of cabinets and furniture with reducedlogistics/transportation costs.

SUMMARY OF THE INVENTION

The foregoing needs are met, to a great extent, by the presentinvention, wherein in aspects of this invention, enhancements areprovided to the existing model of flat packing of cabinets andfurniture.

In an aspect, a flat packed furniture system can include a plurality ofboxes; wherein each box in the plurality of boxes comprises a packagingpiece and a set of furniture parts, such that the set of furniture partsis flat packed inside the packaging piece; such that a plurality ofparts in the plurality of boxes is configured to be assemblable as afurniture item; such that a plurality of packaging pieces in theplurality of boxes is configured to be reused as packaging for thefurniture item.

In a related aspect, the plurality of boxes can further include:

-   -   a) a first box, comprising:        -   i. a first packaging piece; and        -   ii. a first set of furniture parts, wherein the first set of            furniture parts is packaged inside the first packaging            piece;    -   b) A second box, comprising:        -   i. a second packaging piece; and        -   ii. a second set of furniture parts, wherein the second set            of furniture parts is packaged inside the second packaging            piece;    -   c) a third box, comprising:        -   i. a third packaging piece;        -   ii. a fourth packaging piece; and        -   iii. a third set of furniture parts, wherein the third set            of furniture parts is packaged inside the third and fourth            packaging pieces;    -   wherein the first, second, and third sets of furniture parts are        configured to be assemblable as a furniture item;    -   such that the packaging pieces are configured to be reused as        packaging for the furniture item, such that the packaging pieces        are configured to cover outer surfaces of the assembled        furniture item.

In an aspect, a method for flat packing furniture, can include:

-   -   a) Flat packing a furniture item, wherein a plurality of parts        for a furniture item are flat packaged inside a plurality of        packaging pieces, producing a plurality of boxes;    -   b) Shipping the flat packed furniture item, wherein the        plurality of boxes is shipped from a manufacturing location to a        reseller location;    -   c) Unpacking the flat packed furniture item, wherein the        plurality of parts is unpackaged from the plurality of boxes;    -   d) Assembling the furniture item, wherein the furniture item is        assembled from the plurality of parts;    -   e) Re-packing the assembled furniture item, wherein the        assembled furniture item is re-packaged with the plurality of        packaging pieces; and    -   f) Re-shipping the assembled furniture item, wherein the        re-packaged furniture item is shipped from the reseller location        to a customer location.

There has thus been outlined, rather broadly, certain embodiments of theinvention in order that the detailed description thereof herein may bebetter understood, and in order that the present contribution to the artmay be better appreciated. There are, of course, additional embodimentsof the invention that will be described below and which will form thesubject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of embodiments inaddition to those described and of being practiced and carried out invarious ways. In addition, it is to be understood that the phraseologyand terminology employed herein, as well as the abstract, are for thepurpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conceptionupon which this disclosure is based may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a flat packed furniture system in aninitial configuration for shipping, according to an embodiment of theinvention.

FIG. 2A is a left front perspective view of a furniture item assembledfrom the flat packed furniture system in an initial configuration forshipping, according to an embodiment of the invention.

FIG. 2B is a right front perspective view of the furniture item shown inFIG. 2A.

FIG. 2C is a right rear perspective view of the furniture item shown inFIG. 2A.

FIG. 2D is a left bottom perspective view of the furniture item shown inFIG. 2A.

FIG. 3A is a top elevation view of a first packaging piece of the flatpacked furniture system, according to an embodiment of the invention.

FIG. 3B is a top elevation view of a second packaging piece of the flatpacked furniture system, according to an embodiment of the invention.

FIG. 3C is a top elevation view of a third packaging piece of the flatpacked furniture system, according to an embodiment of the invention.

FIG. 3D is a top elevation view of a fourth packaging piece of the flatpacked furniture system, according to an embodiment of the invention.

FIG. 4A is a perspective view of a first set of furniture parts of theflat packed furniture system, according to an embodiment of theinvention.

FIG. 4B is a perspective view of a second set of furniture parts of theflat packed furniture system, according to an embodiment of theinvention.

FIG. 4C is a perspective view of a third set of furniture parts of theflat packed furniture system, according to an embodiment of theinvention.

FIG. 5A is a flowchart illustrating steps that may be followed, inaccordance with one embodiment of a method or process of flat packingfurniture.

FIG. 5B is a flowchart illustrating a sequence of locations, inaccordance with one embodiment of a method or process of flat packingfurniture.

FIG. 6A is a left front perspective view of a furniture item assembledfrom the flat packed furniture system in an initial configuration forshipping and packaged with reused packaging pieces, according to anembodiment of the invention.

FIG. 6B is a right front perspective view of the furniture item packagedwith reused packaging pieces shown in FIG. 6A.

FIG. 6C is a right rear perspective view of the furniture item packagedwith reused packaging pieces shown in FIG. 6A.

FIG. 6D is a left bottom perspective view of the furniture item packagedwith reused packaging pieces shown in FIG. 6A.

DETAILED DESCRIPTION

Before describing the invention in detail, it should be observed thatthe present invention resides primarily in a novel and non-obviouscombination of elements and process steps. So as not to obscure thedisclosure with details that will readily be apparent to those skilledin the art, certain conventional elements and steps have been presentedwith lesser detail, while the drawings and specification describe ingreater detail other elements and steps pertinent to understanding theinvention.

The following embodiments are not intended to define limits as to thestructure or method of the invention, but only to provide exemplaryconstructions. The embodiments are permissive rather than mandatory andillustrative rather than exhaustive.

The final shape of many of the flat packet products when assembled arerectangular with 6 planes—left and right, front and back, and top andbottom. The standard packaging is 1 box per assembly or if the productis modular, 1 box per group of modular components.

The proposed invention is associated with the growing market requiringrepacking of the modular flat packed product when it is assembled.

In the following, we describe the structure of an embodiment of a flatpacked furniture system 100 with reference to FIG. 1, in such mannerthat like reference numerals refer to like components throughout; aconvention that we shall employ for the remainder of this specification.

In an embodiment a flat packed furniture system 100, which also can bereferred to as a modular flat packed furniture system 100, can comprisea plurality of boxes 110 120 130, such that each box 110 120 130contains packaging pieces and parts for a furniture item, such that theplurality of parts from each box 110 120 130 can be assembled as thefurniture item, and such that the packaging pieces from each box 110 120130, can be reused as packaging for the furniture item.

In a related embodiment, as shown in FIGS. 1, 2A-2D, 3A-3D, and 4A-4D, aflat packed furniture system 100 can include:

-   -   a) A first box 110, which can include:        -   i. A first packaging piece 112, as shown in FIGS. 1 and 3A;            and        -   ii. A first set of furniture parts 410, as shown in FIG. 4A,            wherein the first set of furniture parts 410 is packaged            inside the first packaging piece 112;    -   b) A second box 120, which can include:        -   i. A second packaging piece 122, as shown in FIGS. 1 and 3B;            and        -   ii. A second set of furniture parts 420, as shown in FIG.            4B, wherein the second set of furniture parts 420 is            packaged inside the second packaging piece 122;    -   c) A third box 130, which can include:        -   i. a third packaging piece 132, as shown in FIGS. 1 and 3C;        -   ii. a fourth packaging piece 334, as shown in FIG. 3D; and        -   iii. A third set of furniture parts 430, as shown in FIG.            4C, wherein the third set of furniture parts 430 is packaged            inside the third and fourth packaging pieces 132 334;        -   such that the third and fourth packaging pieces 132 334 are            mounted on opposing sides, in a shoebox type configuration;    -   wherein the first, second, and third sets of furniture parts 410        420 430 are configured to be assemblable as an assembled        furniture item 200;    -   such that the packaging pieces 112 122 132 334 are configured to        be reused as packaging for the furniture item 200, such that the        packaging pieces 112 122 132 334 are configured to cover outer        surfaces of the assembled furniture item 200.

In related embodiments, the packaging pieces 112 122 132 334 can be flatpieces of cardboard, made of types of cardboard commonly used forboxes/packaging, but can also be made of other flat pieces made ofmaterials suitable for packaging.

In related embodiments, the flat packed furniture system 100 can beconfigured such that the first, second, and third sets of furnitureparts 410 420 430 are configured to be assemblable as a cabinet 200,which can include B30 and W1830 cabinet sizes, and other cabinet sizesand designs, including standardized and proprietary sizes and design.

In a related embodiment, the flat packed furniture system 100 can beconfigured such that:

-   -   a) the first set of furniture parts 410 can include face parts        of a cabinet 200, including:        -   i. a face panel 213, which is a part of a front side 203 of            the cabinet 200;        -   ii. doors 223, which are part of a front side 203 of the            cabinet 200;        -   iii. a back panel 206;    -   b) the second set of furniture parts 420 can include gut parts        of a cabinet 200, including:        -   i. optionally, a top panel 424;        -   ii. a bottom panel 205;        -   iii. a toe panel 208;        -   iv. parts for drawer boxes 426;        -   v. corner blocks 422; and        -   vi. brackets, screws and other hardware 428;    -   c) the third set of furniture parts 430 can include side parts        of a cabinet 200, including:        -   iv. a right side 202; and        -   v. a left side 201.

In related embodiments, the flat packed furniture system 100 is amodular packaging system adapted for reuse of packaging, such that flatpacked furniture system 100 optimizes for both reduced storage/inventorycost and reduced packaging cost, such that when a manufacturer producesa portfolio of cabinets, including a first plurality, n, of cabinetmodels, each cabinet model including a second plurality, c, of coloroptions, then the manufacturer must produce:

-   -   a) n different first sets of furniture parts 410, which are face        parts, each in c different color options;    -   b) one second set of furniture parts 420, which are gut parts        that are generic (i.e. the same) for all combinations of cabinet        models and colors; and    -   c) c different third sets of furniture parts 430, which are side        parts that are generic (i.e. the same) for all combinations of        cabinet models, and only vary depending on the color option        selection;    -   whereby when the manufacturer needs to produce/stock a new        cabinet model, the manufacturer only needs to produce new        versions of the first box 110 with a first set of furniture        parts 410, since both the second and third boxes 120 130 with        respectively second and third sets of furniture parts 420 430        are generic to the cabinet model version. Some high-end        manufacturers package all parts in one large box, thereby        maximizing storage/inventory cost and minimizing, and some mass        market manufacturers will package a cabinet in a high number of        boxes, such as for example nine boxes. The modular flat packed        furniture system 100, uses a novel approach of separating parts        in face parts, gut parts, and side parts, in respectively the        first, second, and third boxes 110 120 130, and thereby        optimizes for both minimal storage/inventory cost and for        minimal packaging cost. The modular flat packed furniture system        100 further reduces packaging cost by facilitating reuse of the        packaging pieces 112 122 132 334 of the first, second, and third        boxes 110 120 130 for packaging of an assembled cabinet 200, in        preparation for further shipment when the cabinet 200 has been        assembled from the face, gut, side parts of respectively the        first, second, and third boxes 110 120 130.

In a related embodiment, wherein the cabinet 200 is a B12 cabinet, theflat packed furniture system 100 can be configured such that:

-   -   a) the first box 110 can be 12″ wide, 30″ tall, and 2″ deep;    -   b) the second box 120 can be 12″ wide, 24″ tall, and 3″ deep;    -   c) the third box 130 can be 24″ wide, 34½″ tall, and 1″ deep.

In a related embodiment, as shown in FIG. 3A, the first packaging piece112 can be configured for packaging reuse, such that the first packagingpiece 112 can include attach/fold pieces connected by perforatedborders, including

-   -   a) a top center attachment piece 304 a, which is configured to        be aligned with a top side 204 of the cabinet 200,        -   such that the top center attachment piece 304 a is            positioned in a top center of the first packaging piece 112,            between a top fold piece 306 a and a bottom center            attachment piece 303 a;    -   b) a bottom center attachment piece 303 a, which is configured        to be aligned with a front face 203 of the cabinet 200,        -   such that the bottom center attachment piece 303 a is            positioned in a bottom center of the first packaging piece            112, between the top center attachment piece 304 a and            bottom fold piece 307 a, such that a bottom side of the top            center attachment piece 304 a is connected to a top side of            the bottom center attachment piece 303 a, via an            intermediate fold piece;    -   c) a top fold piece 306 a, which is configured to fold onto a        back panel 206 of the cabinet 200,        -   such that the top fold piece 306 a is positioned in a top of            the first packaging piece 112, and connected to a top side            of the top center attachment piece 304 a;    -   d) a top left side fold piece 301 a, which is configured to fold        onto a left side 201 of the cabinet 200,        -   such that the top left side fold piece 301 a is positioned            in a top left side of the first packaging piece 112, and            connected to a left side of the top center attachment piece            304 a;    -   e) a top right side fold piece 302 a, which is configured to        fold onto a right side 202 of the cabinet 200,        -   such that the top right side fold piece 302 a is positioned            in a top right side of the first packaging piece 112, and            connected to a right side of the top center attachment piece            304 a;    -   f) a bottom left side fold piece 311 a, which is configured to        fold onto a left side 201 of the cabinet 200,        -   such that the bottom left side fold piece 311 a is            positioned in a bottom left side of the first packaging            piece 112, and connected to a left side of the bottom center            attachment piece 303 a;    -   g) a bottom right side fold piece 312 a, which is configured to        fold onto a right side 202 of the cabinet 200,        -   such that the bottom right side fold piece 312 a is            positioned in a bottom right side of the first packaging            piece 112, and connected to a right side of the bottom            center attachment piece 303 a; and    -   h) a bottom fold piece 307 a, which is configured to fold onto a        bottom panel 205 of the cabinet 200,        -   such that the bottom fold piece 307 a is positioned in a            bottom of the first packaging piece 112, and connected to a            bottom side of the bottom center attachment piece 303 a.

In a related embodiment, as shown in FIG. 3B, the second packaging piece122 can be configured for packaging reuse, such that the secondpackaging piece 122 can include attach/fold pieces connected byperforated borders, including

-   -   a) a top fold piece 306 b, which is configured to be aligned        with a back panel 206 of the cabinet 200,        -   such that the top fold piece 306 b is positioned in a top of            the second packaging piece 122, and connected to a top side            of the center attachment piece 305 b;    -   b) a center attachment piece 305 b, which is configured to be        aligned with a bottom panel 205 of the cabinet 200,        -   such that the center attachment piece 305 b is positioned in            a center of the second packaging piece 122, between a top            fold piece 306 b and a bottom fold piece 308 b;    -   c) a bottom fold piece 308 b, which is configured to fold onto a        toe panel 208 of the cabinet 200,        -   such that the bottom fold piece 308 b is positioned in a            bottom of the second packaging piece 122, and connected to a            bottom side of the center attachment piece 305 b;    -   d) a bottom right side fold piece 302 b, which is configured to        fold onto a right side 202 of the cabinet 200,        -   such that the bottom right side fold piece 302 b is            positioned in a bottom right side of the second packaging            piece 122, and connected to a right side of the center            attachment piece 305 b;    -   e) a bottom left side fold piece 301 b, which is configured to        fold onto a left side 201 of the cabinet 200,        -   such that the bottom left side fold piece 301 b is            positioned in a bottom left side of the second packaging            piece 122, and connected to a left side of the center            attachment piece 305 b;    -   f) a top right side fold piece 312 b, which is configured to        fold onto a right side 202 of the cabinet 200,        -   such that the top right side fold piece 312 b is positioned            in a top right side of the second packaging piece 122, and            connected to a right side of the top fold piece 306 b; and    -   g) a top left side fold piece 311 b, which is configured to fold        onto a left side 201 of the cabinet 200,        -   such that the top left side fold piece 311 b is positioned            in a top left side of the second packaging piece 122, and            connected to a left side of the top fold piece 306 b.

In a related embodiment, as shown in FIG. 3C, the third packaging piece132 can be configured for packaging reuse, such that the third packagingpiece 132 can include attach/fold pieces connected by perforatedborders, including

-   -   a) a center attachment piece 301 c, which is configured to be        aligned with a left panel 201 of the cabinet 200,        -   such that the center attachment piece 301 c is positioned in            a center of the third packaging piece 132, below a top fold            piece 301 c-i and above a bottom fold piece 311 c-i;    -   b) a top fold piece 301 c-i, which is configured to fold back        onto an inner side 211 of the left panel 201 of the cabinet 200,        -   such that the top fold piece 301 c-i is positioned in a top            of the third packaging piece 132, and connected to a top            side of the center attachment piece 301 c;    -   c) a left side fold piece 306 c, which is configured to fold        onto a back panel 206 of the cabinet 200,        -   such that the left side fold piece 306 c is positioned in a            left side of the third packaging piece 132, and connected to            a left side of the center attachment piece 301 c;    -   d) a right side fold piece 303 c, which is configured to fold        onto a front side 203 of the cabinet 200,        -   such that the right side fold piece 303 c is positioned in a            right side of the third packaging piece 132, and connected            to a right side of the center attachment piece 301 c;    -   e) a right bottom corner fold piece 309 c, which is configured        to fold onto a toe panel 208 of the cabinet 200,        -   such that the right bottom corner fold piece 309 c is            positioned in a right bottom corner of the third packaging            piece 132, and connected to a right bottom corner of the            center attachment piece 301 c; and    -   f) a bottom fold piece 311 c-i, which is configured to fold back        onto an inner side 211 of the left panel 201 of the cabinet 200,        -   such that the bottom fold piece 311 c-i is positioned in a            bottom of the third packaging piece 132, and connected to a            bottom side of the center attachment piece 301 c.

In a related embodiment, as shown in FIG. 3D, the fourth packaging piece334 can be configured for packaging reuse, such that the fourthpackaging piece 334 can include attach/fold pieces connected byperforated borders, including

-   -   a) a center attachment piece 302 d, which is configured to be        aligned with a right panel 202 of the cabinet 200,        -   such that the center attachment piece 302 d is positioned in            a center of the fourth packaging piece 334, below a top fold            piece 302 d-i and above a bottom fold piece 312 d-i;    -   b) a top fold piece 302 d-i, which is configured to fold back        onto an inner side 212 of the right panel 202 of the cabinet        200,        -   such that the top fold piece 302 d-i is positioned in a top            of the fourth packaging piece 334, and connected to a top            side of the center attachment piece 302 d;    -   c) a right side fold piece 306 d, which is configured to fold        onto a back panel 206 of the cabinet 200,        -   such that the right side fold piece 306 d is positioned in a            right side of the fourth packaging piece 334, and connected            to a right side of the center attachment piece 302 d;    -   d) a left side fold piece 303 d, which is configured to fold        onto a front side 203 of the cabinet 200,        -   such that the left side fold piece 303 d is positioned in a            left side of the fourth packaging piece 334, and connected            to a left side of the center attachment piece 302 d;    -   e) a left bottom corner fold piece 309 d, which is configured to        fold onto a toe panel 208 of the cabinet 200,        -   such that the left bottom corner fold piece 309 d is            positioned in a left bottom corner of the fourth packaging            piece 334, and connected to a left bottom corner of the            center attachment piece 302 d; and    -   f) a bottom fold piece 312 d-i, which is configured to fold back        onto an inner side 212 of the right panel 202 of the cabinet        200,        -   such that the bottom fold piece 312 d-i is positioned in a            bottom of the fourth packaging piece 334, and connected to a            bottom side of the center attachment piece 302 d.

In a further related embodiment, FIGS. 6A, 6B, 6C, and 6D shows thefirst, second, third, and fourth packaging pieces 112 122 132 334 usedfor packaging reuse, such that the cabinet 200 is packaged with thefirst, second, third, and fourth packaging pieces 112 122 132 334, toform a repackaged cabinet 600. The perspective views of FIGS. 6A, 6B,6C, and 6D correspond substantially to the views of FIGS. 6A, 6B, 6C,and 6D, respectively, with the first, second, third, and fourthpackaging pieces 112 122 132 334 added.

In related embodiments, when the first, second, third, and fourthpackaging pieces 112 122 132 334 are used for packaging reuse to packagethe assembled cabinet 200, the first, second, third, and fourthpackaging pieces 112 122 132 334 can be secured using packaging tape,staples, and/or other packaging fasteners.

In a related embodiment, as shown in FIGS. 6A, 6B, 6C, and 6D:

-   -   a) The third and fourth packaging pieces 132 334 can be attached        to the cabinet first, for example using tape and/or staples,        such that the third and fourth packaging pieces 132 334 are        innermost positioned;    -   b) The second packaging piece 122 can be attached next, for        example using tape and/or staples, and partially overlapping the        third and fourth packaging pieces 132 334, such that the second        packaging piece 122 is intermediately positioned; and    -   c) The first packaging piece 112 can be attached lastly, for        example using tape and/or staples, and partially overlapping the        third, fourth, and second packaging pieces 132 334 122, such        that the first packaging piece 112 is outermost positioned.

In an embodiment, as illustrated in FIGS. 5A and 5B, a method for flatpacking furniture 500, can include:

-   -   a) Flat packing a furniture item 502, wherein a plurality of        parts for a furniture item 200 are flat packaged inside a        plurality of packaging pieces 112 122 132 334, producing a        plurality of boxes 110 120 130;    -   b) Shipping the flat packed furniture item 504, wherein the        plurality of boxes is shipped from a manufacturing location 552        to a reseller location 554, as shown in FIG. 5B, showing the        sequence of locations 550;    -   c) Unpacking the flat packed furniture item 506, wherein the        plurality of parts, comprising a plurality of sets of furniture        parts, is unpackaged from the plurality of boxes;    -   d) Assembling the furniture item 508, wherein the furniture 200        item is assembled from the plurality of parts, to form an        assembled furniture item 200;    -   e) Re-packing the furniture item 510, wherein the assembled        furniture item 200 is re-packaged with the plurality of        packaging pieces 112 122 132 334, to form a repackaged furniture        item 600; and    -   f) Re-shipping the furniture item 512, wherein the re-packaged        furniture item 600 is shipped from the reseller location 554 to        a customer location 556.

Here has thus been described a multitude of embodiments of the flatpacked furniture system 100, and methods related thereto, which can beemployed in numerous modes of usage.

The many features and advantages of the invention are apparent from thedetailed specification, and thus, it is intended by the appended claimsto cover all such features and advantages of the invention, which fallwithin the true spirit and scope of the invention.

Many such alternative configurations are readily apparent, and should beconsidered fully included in this specification and the claims appendedhereto. Accordingly, since numerous modifications and variations willreadily occur to those skilled in the art, it is not desired to limitthe invention to the exact construction and operation illustrated anddescribed, and thus, all suitable modifications and equivalents may beresorted to, falling within the scope of the invention.

What is claimed is:
 1. A method for flat packing furniture, comprising:a) flat packing a furniture item, wherein a plurality of parts for thefurniture item are flat packaged inside a plurality of packaging pieces,producing a plurality of boxes; b) shipping the flat packed furnitureitem, wherein the plurality of boxes is shipped from a manufacturinglocation to a reseller location; c) unpacking the flat packed furnitureitem, wherein the plurality of parts, comprising a plurality of sets offurniture parts, is unpackaged from the plurality of boxes; d)assembling the furniture item, wherein the furniture item is assembledfrom the plurality of parts; and e) re-packing the furniture item,wherein the assembled furniture item is re-packaged with the pluralityof packaging pieces.
 2. The method for flat packing furniture of claim1, further comprising: re-shipping the furniture item; wherein there-packaged furniture item is shipped from the reseller location to acustomer location.
 3. The method for flat packing furniture of claim 1,wherein the plurality of boxes further comprises: a) a first box,comprising: a first packaging piece; and a first set of furniture parts,wherein the first set of furniture parts is flat packed inside the firstpackaging piece; b) a second box, comprising: a second packaging piece;and a second set of furniture parts, wherein the second set of furnitureparts is flat packed inside the second packaging piece; and c) a thirdbox, comprising: a third packaging piece; a fourth packaging piece; anda third set of furniture parts, wherein the third set of furniture partsis flat packed inside the third and fourth packaging pieces; wherein thefirst, second, and third sets of furniture parts are configured to beassemblable as the furniture item; such that the packaging pieces areconfigured to be reused as packaging for the furniture item, such thatthe first, second, third, and fourth packaging pieces are configured tocover outer surfaces of the furniture item.
 4. The method for flatpacking furniture of claim 1, wherein the furniture item is a cabinet.5. The method for flat packing furniture of claim 3, wherein thefurniture item is a cabinet, and wherein: a) the first set of furnitureparts comprises face parts of the cabinet, comprising: a face panel,which is a part of a front side of the cabinet; doors, which are part ofthe front side of the cabinet; and a back panel; b) the second set offurniture parts comprise gut parts of the cabinet, comprising: a bottompanel; a toe panel; and parts for drawer boxes; and c) the third set offurniture parts comprise side parts of the cabinet, comprising: a rightside; and a left side.
 6. The method for flat packing furniture of claim5, wherein the second set of furniture parts further comprises a toppanel.
 7. The method for flat packing furniture of claim 3, wherein thefurniture item is a cabinet, wherein the first packaging piece comprisesconnected pieces, comprising: a) a top center attachment piece, which isconfigured to be aligned with a top side of the cabinet; b) a bottomcenter attachment piece, which is configured to be aligned with a frontface of the cabinet, such that a bottom side of the top centerattachment piece is connected to a top side of the bottom centerattachment piece; c) a top fold piece, which is configured to fold ontoa back panel of the cabinet, such that the top fold piece is connectedto a top side of the top center attachment piece; d) a top left sidefold piece, which is configured to fold onto a left side of the cabinet,such that the top left side fold piece is connected to a left side ofthe top center attachment piece; e) a top right side fold piece, whichis configured to fold onto a right side of the cabinet, such that thetop right side fold piece is connected to a right side of the top centerattachment piece; f) a bottom left side fold piece, which is configuredto fold onto a left side of the cabinet, such that the bottom left sidefold piece is connected to a left side of the bottom center attachmentpiece; g) a bottom right side fold piece, which is configured to foldonto a right side of the cabinet, such that the bottom right side foldpiece is connected to a right side of the bottom center attachmentpiece; and h) a bottom fold piece, which is configured to fold onto abottom panel of the cabinet, such that the bottom fold piece isconnected to a bottom side of the bottom center attachment piece.
 8. Themethod for flat packing furniture of claim 7, wherein the connectedpieces are connected by perforated borders.
 9. The method for flatpacking furniture of claim 3, wherein the furniture item is a cabinet,wherein the second packaging piece comprises connected pieces,comprising: a) a center attachment piece, which is configured to bealigned with a bottom panel of the cabinet; b) a top fold piece, whichis configured to be aligned with a back panel of the cabinet, such thatthe top fold piece is connected to a top side of the center attachmentpiece; c) a bottom fold piece, which is configured to fold onto a toepanel of the cabinet, such that the bottom fold piece is connected to abottom side of the center attachment piece; d) a bottom right side foldpiece, which is configured to fold onto a right side of the cabinet,such that the bottom right side fold piece is connected to a right sideof the center attachment piece; e) a bottom left side fold piece, whichis configured to fold onto a left side of the cabinet, such that thebottom left side fold piece is connected to a left side of the centerattachment piece; f) a top right side fold piece, which is configured tofold onto a right side of the cabinet, such that the top right side foldpiece is connected to a right side of the top fold piece; and g) a topleft side fold piece, which is configured to fold onto a left side ofthe cabinet, such that the top left side fold piece is connected to aleft side of the top fold piece.
 10. The method for flat packingfurniture of claim 3, wherein the furniture item is a cabinet, whereinthe third packaging piece comprises connected pieces, comprising: a) acenter attachment piece, which is configured to be aligned with a leftpanel of the cabinet; b) a top fold piece, which is configured to foldback onto an inner side of the left panel of the cabinet, such that thetop fold piece is connected to a top side of the center attachmentpiece; c) a left side fold piece, which is configured to fold onto aback panel of the cabinet, such that the left side fold piece isconnected to a left side of the center attachment piece; d) a right sidefold piece, which is configured to fold onto a front side of thecabinet, such that the right side fold piece is connected to a rightside of the center attachment piece; and e) a bottom fold piece, whichis configured to fold back onto an inner side of the left panel of thecabinet, such that the bottom fold piece is connected to a bottom sideof the center attachment piece.
 11. The method for flat packingfurniture of claim 3, wherein the furniture item is a cabinet, whereinthe fourth packaging piece comprises connected pieces, comprising: a) acenter attachment piece, which is configured to be aligned with a rightpanel of the cabinet; b) a top fold piece, which is configured to foldback onto an inner side of the right panel of the cabinet, such that thetop fold piece is connected to a top side of the center attachmentpiece; c) a right side fold piece, which is configured to fold onto aback panel of the cabinet, such that the right side fold piece isconnected to a right side of the center attachment piece; d) a left sidefold piece, which is configured to fold onto a front side of thecabinet, such that the left side fold piece is connected to a left sideof the center attachment piece; and e) a bottom fold piece, which isconfigured to fold back onto an inner side of the right panel of thecabinet, such that the bottom fold piece is connected to a bottom sideof the center attachment piece.
 12. A method for flat packing furniture,comprising: a) flat packing a furniture item, wherein a plurality ofparts for the furniture item are flat packaged inside a plurality ofpackaging pieces, producing a plurality of boxes; b) shipping the flatpacked furniture item, wherein the plurality of boxes is shipped from amanufacturing location to a reseller location; c) unpacking the flatpacked furniture item, wherein the plurality of parts, comprising aplurality of sets of furniture parts, is unpackaged from the pluralityof boxes; d) assembling the furniture item, wherein the furniture itemis assembled from the plurality of parts; and e) re-packing thefurniture item, wherein the assembled furniture item is re-packaged withthe plurality of packaging pieces; wherein the plurality of boxesfurther comprises: a first box, comprising: a first packaging piece; anda first set of furniture parts, wherein the first set of furniture partsis flat packed inside the first packaging piece; a second box,comprising: a second packaging piece; and a second set of furnitureparts, wherein the second set of furniture parts is flat packed insidethe second packaging piece; and a third box, comprising: a thirdpackaging piece; a fourth packaging piece; and a third set of furnitureparts, wherein the third set of furniture parts is flat packed insidethe third and fourth packaging pieces; wherein the first, second, andthird sets of furniture parts are configured to be assemblable as thefurniture item; such that the packaging pieces are configured to bereused as packaging for the furniture item, such that the packagingpieces are configured to cover outer surfaces of the furniture item. 13.The method for flat packing furniture of claim 12, further comprising:re-shipping the furniture item; wherein the re-packaged furniture itemis shipped from the reseller location to a customer location.
 14. Themethod for flat packing furniture of claim 12, wherein the furnitureitem is a cabinet, and wherein: a) the first set of furniture partscomprises face parts of the cabinet, comprising: a face panel, which isa part of a front side of the cabinet; doors, which are part of thefront side of the cabinet; and a back panel; b) the second set offurniture parts comprise gut parts of the cabinet, comprising: a bottompanel; a toe panel; and parts for drawer boxes; and c) the third set offurniture parts comprise side parts of the cabinet, comprising: a rightside; and a left side.
 15. The method for flat packing furniture ofclaim 14, wherein the second set of furniture parts further comprises atop panel.
 16. The method for flat packing furniture of claim 12,wherein the furniture item is a cabinet, wherein the first packagingpiece comprises connected pieces, comprising: a) a top center attachmentpiece, which is configured to be aligned with a top side of the cabinet;b) a bottom center attachment piece, which is configured to be alignedwith a front face of the cabinet, such that a bottom side of the topcenter attachment piece is connected to a top side of the bottom centerattachment piece; c) a top fold piece, which is configured to fold ontoa back panel of the cabinet, such that the top fold piece is connectedto a top side of the top center attachment piece; d) a top left sidefold piece, which is configured to fold onto a left side of the cabinet,such that the top left side fold piece is connected to a left side ofthe top center attachment piece; e) a top right side fold piece, whichis configured to fold onto a right side of the cabinet, such that thetop right side fold piece is connected to a right side of the top centerattachment piece; f) a bottom left side fold piece, which is configuredto fold onto a left side of the cabinet, such that the bottom left sidefold piece is connected to a left side of the bottom center attachmentpiece; g) a bottom right side fold piece, which is configured to foldonto a right side of the cabinet, such that the bottom right side foldpiece is connected to a right side of the bottom center attachmentpiece; and h) a bottom fold piece, which is configured to fold onto abottom panel of the cabinet, such that the bottom fold piece isconnected to a bottom side of the bottom center attachment piece. 17.The method for flat packing furniture of claim 16, wherein the connectedpieces are connected by perforated borders.
 18. The method for flatpacking furniture of claim 12, wherein the furniture item is a cabinet,wherein the second packaging piece comprises connected pieces,comprising: a) a center attachment piece, which is configured to bealigned with a bottom panel of the cabinet; b) a top fold piece, whichis configured to be aligned with a back panel of the cabinet, such thatthe top fold piece is connected to a top side of the center attachmentpiece; c) a bottom fold piece, which is configured to fold onto a toepanel of the cabinet, such that the bottom fold piece is connected to abottom side of the center attachment piece; d) a bottom right side foldpiece, which is configured to fold onto a right side of the cabinet,such that the bottom right side fold piece is connected to a right sideof the center attachment piece; e) a bottom left side fold piece, whichis configured to fold onto a left side of the cabinet, such that thebottom left side fold piece is connected to a left side of the centerattachment piece; f) a top right side fold piece, which is configured tofold onto a right side of the cabinet, such that the top right side foldpiece is connected to a right side of the top fold piece; and g) a topleft side fold piece, which is configured to fold onto a left side ofthe cabinet, such that the top left side fold piece is connected to aleft side of the top fold piece.
 19. The method for flat packingfurniture of claim 12, wherein the furniture item is a cabinet, whereinthe third packaging piece comprises connected pieces, comprising: a) acenter attachment piece, which is configured to be aligned with a leftpanel of the cabinet; b) a top fold piece, which is configured to foldback onto an inner side of the left panel of the cabinet, such that thetop fold piece is connected to a top side of the center attachmentpiece; c) a left side fold piece, which is configured to fold onto aback panel of the cabinet, such that the left side fold piece isconnected to a left side of the center attachment piece; d) a right sidefold piece, which is configured to fold onto a front side of thecabinet, such that the right side fold piece is connected to a rightside of the center attachment piece; and e) a bottom fold piece, whichis configured to fold back onto an inner side of the left panel of thecabinet, such that the bottom fold piece is connected to a bottom sideof the center attachment piece.
 20. The method for flat packingfurniture of claim 12, wherein the furniture item is a cabinet, whereinthe fourth packaging piece comprises connected pieces, comprising: a) acenter attachment piece, which is configured to be aligned with a rightpanel of the cabinet; b) a top fold piece, which is configured to foldback onto an inner side of the right panel of the cabinet, such that thetop fold piece is connected to a top side of the center attachmentpiece; c) a right side fold piece, which is configured to fold onto aback panel of the cabinet, such that the right side fold piece isconnected to a right side of the center attachment piece; d) a left sidefold piece, which is configured to fold onto a front side of thecabinet, such that the left side fold piece is connected to a left sideof the center attachment piece; and e) a bottom fold piece, which isconfigured to fold back onto an inner side of the right panel of thecabinet, such that the bottom fold piece is connected to a bottom sideof the center attachment piece.